Cavalier, Sunfire 2001-2005

Removal & Installation

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CAUTION
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF , unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove the fuel tank.
    NOTE
    The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Use a shop towel to absorb any leakage.

  8.  
  9. While holding the modular fuel sender assembly down, remove the snap ring from designated slots located on the retainer .

    Click image to see an enlarged view

    Fig. Illustration showing the components of the fuel sending unit: snap ring (1); retainer (2); fuel sender unit (3); and fuel tank (4).

  10.  

To install:

  1. Install a new O-ring on the modular fuel sender.
  2.  
  3. Install the modular fuel sender to the fuel tank.
  4.  
  5. Align the tab on front of the modular fuel sender with slot on front of the retainer snap ring.
  6.  
  7. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.
    NOTE
    Be sure that the snap ring is fully seated within the tab slots.

  8.  
  9. Insert the snap ring into the designated slots.
  10.  
  11. Install the fuel tank.
  12.  
  13. Lower the vehicle.
  14.  
  15. Refill the fuel tank.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for fuel leaks through the following steps:


    1. Turn the ignition switch to the ON position for two seconds
    2.  
    3. Turn the ignition switch to the OFF position for ten seconds.
    4.  
    5. Turn the ignition switch to the ON position
    6.  
    7. Check for fuel leaks.
    8.  

  20.  

 
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